I've been suffering with a dropped windshield frame cover for a while, i've seen a few others on the forum with the same problem......rattles like hell! The cover shields the electric motor that fastens down the roof to the windshield, part no6 in the diagram
This is what it should look like and then when it drops and as I say the rattling drives you nuts!
I found a rather under engineered bracket had sheared off and a rather tasty stress crack too! Obviously the design of the shield had been given to a junior engineer who knew zero about plastics requiring a radius on corners to prevent stress cracks.
This is what it should look like, the square hole sits on a nylon bush which is screwed to the roof frame, sorry forgot to take a pic of the bush. With the top of the square moulding missing there is nothing to stop the shield from dropping down and rattle away.
And another stress crack too!
I looked online for a new shield.....£250 for used, stuff that I aint paying that money for a piece of cheap flimsy plastic.
After a bit of research I came across Q-bond which I got from Ebay for £8.50. You get 2 bottles of glue (type of superglue) and 2 bottles of powder (black and Grey) It can be used to mould new plastic.
I used blue tack to make a simple mould. The nylon bush measures 8x7mm so I made the mould slightly larger as it is easier to add rather than take away from a square hole.
After roughing up the surface I formed a rudimentary outer part to the mould and filled with powder in stages. It is best to put the powder in small amounts and build it up in layers, if you don't do this the glue won't have time to wet all the powder as it sets in 10 secs and is at full strength in 10 secs! There is a small amount of smoke when it sets so there is thermal chemical reaction
I removed the bluetack and added more Q-bond to the top of the newly formed plastic as the top part is where the weight is carried. I also fixed the stress cracks. I then filed the plastic to fit and did a test fit, there was approx 1-2mm vertical movement that was solved with a slither of rubber (old cycle innertube)
While it ain't pretty to look at (doesn't matter as it is hidden) it does work perfectly, cover lifted and no more rattles!
You do need to be careful with the glue as it will stick your fingers together and stick your hand to plastic!
This is what it should look like and then when it drops and as I say the rattling drives you nuts!
I found a rather under engineered bracket had sheared off and a rather tasty stress crack too! Obviously the design of the shield had been given to a junior engineer who knew zero about plastics requiring a radius on corners to prevent stress cracks.
This is what it should look like, the square hole sits on a nylon bush which is screwed to the roof frame, sorry forgot to take a pic of the bush. With the top of the square moulding missing there is nothing to stop the shield from dropping down and rattle away.
And another stress crack too!
I looked online for a new shield.....£250 for used, stuff that I aint paying that money for a piece of cheap flimsy plastic.
After a bit of research I came across Q-bond which I got from Ebay for £8.50. You get 2 bottles of glue (type of superglue) and 2 bottles of powder (black and Grey) It can be used to mould new plastic.
I used blue tack to make a simple mould. The nylon bush measures 8x7mm so I made the mould slightly larger as it is easier to add rather than take away from a square hole.
After roughing up the surface I formed a rudimentary outer part to the mould and filled with powder in stages. It is best to put the powder in small amounts and build it up in layers, if you don't do this the glue won't have time to wet all the powder as it sets in 10 secs and is at full strength in 10 secs! There is a small amount of smoke when it sets so there is thermal chemical reaction
I removed the bluetack and added more Q-bond to the top of the newly formed plastic as the top part is where the weight is carried. I also fixed the stress cracks. I then filed the plastic to fit and did a test fit, there was approx 1-2mm vertical movement that was solved with a slither of rubber (old cycle innertube)
While it ain't pretty to look at (doesn't matter as it is hidden) it does work perfectly, cover lifted and no more rattles!
You do need to be careful with the glue as it will stick your fingers together and stick your hand to plastic!
